Compressed coreless roll of sheet product having a center indicator

ABSTRACT

Embodiments of a compressed and coreless roll of sheet product having a center indicator are disclosed. According to an embodiment of the present invention, a compressed coreless roll of sheet product is provided. The compressed coreless roll of sheet product includes a sheet product having a first end and a second end. The sheet product is wound about an axis beginning with the first end and ending with the second end to partially define an axial cavity along the axis. The first end includes an indicator that is visible when the sheet product roll is compressed such that the axial cavity is substantially collapsed.

PRIORITY CLAIM

This application is based on U.S. Provisional Patent Application No.62/476,915, filed Mar. 27, 2017, which is hereby incorporated byreference in its entirety.

BACKGROUND

The present disclosure relates generally to sheet products and, moreparticularly, to a compressed coreless roll of sheet product having acenter indicator.

Sheet products, such as tissues, towels, napkins, etc., are often woundabout a winding axis to form a roll that defines a cavity along theaxis. In some examples, the cavity contains a core around which thesheet product is wound. The core may include a paper, cardboard,plastic, or other rigid or semi-rigid material that substantiallymaintains the shape of the cavity. In other examples, the cavity doesnot contain a core. In such cases, the cavity is said to be hollowand/or coreless.

SUMMARY

According to embodiments of the present disclosure, techniques includingmethods, systems, and/or apparatus for forming a compressed corelessroll of sheet product having a center indicator are provided.

According to an embodiment of the present invention, a compressedcoreless roll of sheet product is provided. The compressed coreless rollof sheet product includes a sheet product having a first end and asecond end. The sheet product is wound about an axis beginning with thefirst end and ending at the second end to partially define an axialcavity along the axis. The first end includes an indicator that isvisible when the sheet product roll is compressed such that the axialcavity is substantially collapsed.

According to another embodiment of the present invention, a method forforming a compressed coreless roll of sheet product having an indicatoris provided. The method includes applying an indicator to an end of asheet product. The method further includes winding the sheet productabout a forming core member starting at the end of the sheet product towhich the indicator is applied. The method further includes removing theforming core member to provide a coreless roll of sheet product havingan axial cavity.

According to yet another embodiment of the present invention, acompressed coreless roll of sheet product is produced by way of applyingan indicator to an end of a sheet product. The compressed coreless rollof sheet product is further produced by way of providing a roll of sheetproduct by winding the sheet product about a forming core memberstarting at the end of the sheet product to which the indicator isapplied. The compressed coreless roll of sheet product is furtherproduced by way of removing the forming core member to provide acoreless roll of sheet product having an axial cavity. The compressedcoreless roll of sheet product is further produced by way of compressingthe coreless roll such that the axial cavity is substantially collapsed.The indicator is visible in the substantially collapsed axial cavity.

Additional features and advantages are realized through the techniquesof the present disclosure. Other aspects are described in detail hereinand are considered a part of the disclosure. For a better understandingof the present disclosure with the advantages and the features, refer tothe following description and to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the invention is particularlypointed out and distinctly claimed in the claims at the conclusion ofthe specification. The foregoing and other features, and advantagesthereof, are apparent from the following detailed description taken inconjunction with the accompanying drawings in which:

FIG. 1 depicts an end view of a compressed coreless roll of sheetproduct;

FIG. 2 depicts an end view of a compressed coreless roll of sheetproduct having an indicator according to embodiments of the presentinvention;

FIG. 3 depicts an end view of a coreless roll of sheet product having anindicator according to embodiments of the present invention;

FIG. 4 depicts a method for forming a compressed coreless roll of sheetproduct having an indicator according to embodiments of the presentinvention; and

FIG. 5 depicts a method of producing a compressed coreless roll of sheetproduct having an indicator according to embodiments of the presentinvention.

Additional technical features and benefits are realized through thetechniques of the present invention. Embodiments and aspects of theinvention are described in detail herein and are considered a part ofthe claimed subject matter. For a better understanding, refer to thedetailed description and to the drawings.

DETAILED DESCRIPTION

Embodiments of the present invention provide a compressed coreless rollof sheet product having a center indicator. The term “sheet product” asused herein is inclusive of natural and/or synthetic sheets of paper,cloth, or other materials. Examples of sheet products include, but arenot limited to, tissue, towels, non-wovens, napkins, or other fibrous,film, polymer, or filamentary products.

In general, sheet products are thin in comparison to their length andbreadth and exhibit a relatively flat planar configuration and areflexible to permit folding, rolling, stacking, and the like. The sheetproduct may have perforations extending in lines across its width toseparate individual sheets and facilitate separation or tearing ofindividual sheets from the roll at discrete intervals. Individual sheetsmay be sized as desired to accommodate the many uses of the sheetproducts.

Transportation costs add substantially to the cost of sheet productssold for consumer use as the volume of these products is such that whenthe entire allowable space in a trailer or container is filled withproduct, the weight is typically far less than the load carryingcapacity of the trailer or container. Prime contributors to theexcessive volume of these products are the central void which istypically around 40 mm or so and also to a lesser extent the generallycylindrical external shape of the overall product. In practice, when anarray of sheet products is packaged in a polyethylene overwrap, theexteriors of the roll are flattened to some extent, increasing thepackability of the array of rolls over that which would be predictedbased solely on the uncompressed roll diameter. It seems that consumersdo not find such rolls objectionable, most likely due to substantialrecovery of the cylindrical shape resulting from the resilient nature ofabsorbent paper products.

However, efforts to eliminate the excess volume contributed by thehollow center void have been less successful in consumer markets, asrolls that have been compressed sufficiently to eliminate the hollowcenter space can be difficult for consumers to use. For example, it canbe difficult for a consumer to locate the axial cavity of the rolls toinstall the rolls into a suitable dispenser.

Reference to the axial cavity 12 of the product as “substantiallycollapsed” is to a flattened form as shown in FIG. 1. Preferably, thegap between opposing sides of the axial cavity 12 in the substantiallycollapsed configuration is less than 25 mm, preferably less than 10 mm,more preferably less than 5 mm and still more preferably less than 2 mmon average. In a preferred embodiment, opposing sides of the axialcavity 12 are in contact over a major portion of their area, preferablyover at least about 60%, more preferably over at least about 70%, evenmore preferably over at least about 80%, and most preferably at leastabout 90%, when rolls are in the compressed state in which they areshipped.

“Tissue” rolls or similar terminology refers to cellulosic fiber tissueproducts, while “bath tissue” rolls must be flushable and are typicallymanufactured without a substantial amount of permanent wet strengthresin; as opposed to paper toweling, or kitchen roll towel, which has asubstantial amount of wet strength resin. Moreover, the most preferredbath tissue is predominantly (over 50% dry weight) composed of hardwoodfiber such as eucalyptus fiber, although many grades, particularlycommercial and economy grades, have ever increasing recycled content ofuncertain origin. Bath tissue generally has a basis weight of anywherefrom 8 to 35 lbs per 3000 square foot ream, with 2 and 3 ply productstypically having a basis weight of from 20 to 35 lbs per 3000 squarefoot ream. As mentioned previously, similar savings and advantages arealso realizable with kitchen roll towel as well as any absorbent paperproduct sold in roll form. Preferably, embodiments of the invention areemployed with respect to absorbent papers in which the sheets are notspoiled or defaced by the compression process. Accordingly, embodimentsof the invention can be employed with bath tissue, kitchen roll towel,other paper toweling formats, or even napkin stock.

FIG. 1 depicts an end view of a compressed coreless roll 10 of sheetproduct. The compressed coreless roll 10 of sheet is produced, forexample, by way of providing a roll of absorbent paper sheet by windingthe sheet about a forming core member, removing the forming core membersuch that there is provided a hollow coreless roll of absorbent papersheet with the axial cavity 12, and compressing the hollow coreless rollsuch that the axial cavity 12 is substantially collapsed. A compressed“hollow” or “coreless” roll refers to a roll of tissue from which eithera conventional cylindrical board stock tube has been removed or a rollof tissue from which the central portion of the roll has been removedleaving a hollow cavity therethrough. Note the absence of any hollowcylindrical board stock core in axial cavity 12 of the compressedcoreless roll 10 of FIG. 1.

Prior to compression, central plugs are preferably removed fromsubstantially hollow coreless rolls using various procedures. Subsequentto core removal, a non-compressed hollow coreless roll (not shown) maybe compressed by action of opposed pistons (not shown) bearing againstlateral surfaces of the rolls, resulting in the compressed coreless roll10. Alternatively, a single piston bearing against a roll restrained bya fixed wall may be used.

In some embodiments of the present invention, the plug removed has adiameter of from about 15 mm to 75 mm such that the axial cavity 12 ofthe roll has a diameter of from 15 mm to 75 mm prior to compression ofthe roll, and in some embodiments the forming core member has a diameterof from about 37.5 mm to 42.5 mm such that the axial cavity 12 of theroll has a diameter of from 37.5 mm to 42.5 mm prior to compression ofthe roll.

The forming core member may be a tubular paperboard core or any othersuitable collapsible core member, but the forming core is preferablyremoved prior to completion of roll compression in order to facilitateboth compression and re-forming. In some examples, initial compressionof the roll while still retaining the core may facilitate removal of thecore, particularly if the roll is formed around a conventionalpaperboard core rather than being formed directly on a mandrel or on acollapsible mandrel.

According to an embodiment of the present invention, the compressedcoreless roll 10 is one of many compressed hollow coreless rolls formedas a log during production. The log is then cut into separate rolls(e.g., the compressed coreless roll 10), which may be approximately 3inches to 5 inches in width, for example, for facial sheet products.Each log may be, for example, 100 inches to 135 inches in width.Accordingly, each log may produce many of the compressed hollow corelessrolls. For example, if a log is 120 inches in length and compressedcoreless rolls are desired to be 4 inches in length, the log can produceapproximately 30 compressed coreless rolls. In various embodiments, thedimensions of the log and/or compressed coreless rolls can vary withoutdeparting from the teachings of the present invention.

In an example of retail/consumer facial sheet products, each compressedcoreless roll is approximately 33 feet in length, which can provideapproximately 90 to 100 sheets of sheet product on each log, dependingon the length of each sheet. In an example of commercial facial sheetproducts, each log is approximately 333 feet in length, which canprovide approximately 900 to 1000 sheets of sheet product on each log,depending on the length of each sheet. It should be appreciated that thelength of each compressed coreless roll can vary according to theembodiments of the present invention.

In FIG. 1, compressed coreless roll 10 maintains a flattened shapehaving: a substantially collapsed axial cavity 12, a pair of longersides 14 which may be relatively flattened and may have a centralportion which approaches being generally planar; a pair of shorter sides16, which, at least after initial compression, are more rounded and mayeven approach being generally semi-cylindrical. The compressed corelessroll 10 is characterized largely by a thickness 18 measured from theperpendicular longer sides 14 through the central axis 20 of thesubstantially collapsed axial cavity 12 which corresponds to the centralaxis 20 of the forming core member (not shown) about which the absorbentsheet was wound.

When the axial cavity 12 is substantially collapsed, as depicted in FIG.1, the axial cavity 12 of the compressed coreless roll 10 “disappears”or is otherwise difficult to see or locate. That is, a user of thecompressed coreless roll 10 may be unable to locate the axial cavity 12.

Embodiments of the present invention solve this problem by applying anindicator 30 to an end of the sheet product that makes up the axialcavity 12 of the compressed coreless roll 10. In particular, FIG. 2depicts an end view of a compressed coreless roll 10 of sheet producthaving an indicator 30 according to embodiments of the presentinvention. As can be appreciated, the indicator 30 provides a user ofthe compressed coreless roll 10 with a visual reference for locating theaxial cavity 12 (FIG. 1) of the compressed coreless roll 10. This may beparticularly useful to locate the axial cavity 12 to insert a core pluginto the axial cavity 12, to install the compressed coreless roll 10into a suitable dispenser, etc.

The indicator 30 is applied to an end of the sheet product that is firstwound about a forming core member (not shown) during production. Inembodiments of the present invention, the indicator 30 is applied byspraying the first few inches, first few sheets, etc., of the first endof the sheet product with a substance that is a different color than thesheet product. For example, the indicator 30 can be applied as a liquidspray that contains a coloring agent/dye to cause the portion of thesheet paper to which the product is applied to turn a different color.

According to some embodiments of the present invention, the liquid sprayis colored water having a coloring agent/dye. During the manufacturingprocess of the compressed coreless roll 10, the colored water is applied(e.g., sprayed, etc.) directly onto the first end of the sheet productbefore the sheet product is wound about the forming core member. In someembodiments, the colored water is allowed to dry on the sheet productbefore the winding; however, in some embodiments, the winding occursbefore the colored water is allowed to dry on the sheet product.

According to some embodiments of the present invention, the liquid sprayis colored adhesive. During the manufacturing process of the compressedcoreless roll 10, the colored adhesive is applied (e.g., sprayed, etc.)directly onto the first end of the sheet product before the sheetproduct is wound. Using adhesive is beneficial during the winding toenabling the sheet product to adhere to the forming core member.

In yet another embodiment of the present invention, the indicator 30 canbe printed on a portion of the sheet product using traditional printingtechniques. The indicator 30 may be solid, striped, dotted, or someother pattern that is visually distinguished from the rest of the sheetproduct.

In at least one embodiment of the present invention, the liquid spray isa colored adhesive (also known as “transfer glue”) applied to theforming core member. In such cases, the colored adhesive is printed orextruded on the forming core member. The sheet product is thentemporarily bonded to the forming core member for winding. The coloredadhesive (i.e., transfer glue) contains a dye or other coloring agent tocause the first end of the sheet paper to be a different color, thuscreating the indicator 30.

By changing the color of a portion of the sheet product, the indicator30 appears in visual contrast to the rest of the sheet product of thecompressed coreless roll 10 so that a user can more easily locate theaxial cavity 12.

FIG. 3 depicts an end view of a coreless roll 32 (not compressed) ofsheet product having an indicator 30 according to embodiments of thepresent invention. In the embodiment of FIG. 3, the coreless roll 32 isshown prior to compression and/or after decompression (such as by auser). The indicator 30 is shown as being applied to several layers(i.e., sheets) of the first end of the sheet product.

FIG. 4 (with reference to FIG. 3) depicts a method 40 for forming acompressed coreless roll of sheet product having an indicator 30according to embodiments of the present invention. At block 42, anindicator 30 is applied to an end of a sheet product. Applying theindicator 30 can include applying colored water and/or applying coloredadhesive, such as by spraying the indicator 30 on an end of the sheetproduct or by applying the adhesive to a forming core member.

At block 44, the sheet product is wound about a forming core memberstarting at the end of the sheet product to which the indicator 30 isapplied. At block 46, the forming core member is removed to provide acoreless roll of sheet product having an axial cavity 12.

In embodiments of the present invention, the method 40 further includescompressing the coreless roll such that the axial cavity 12 issubstantially collapsed. Once compressed, the indicator 30 is visible inthe substantially collapsed axial cavity 12.

Additional processes also may be included, and it should be understoodthat the processes depicted in FIG. 4 represent illustrations and thatother processes may be added or existing processes may be removed,modified, or rearranged without departing from the scope and spirit ofthe present disclosure.

FIG. 5 (with reference to FIG. 3) depicts a method 50 of producing acompressed coreless roll of sheet product having an indicator 30according to embodiments of the present invention. At block 52, anindicator 30 is applied to an end of a sheet product. Applying theindicator 30 can include applying colored water and/or applying coloredadhesive, such as by spraying the indicator 30 on an end of the sheetproduct or by applying the adhesive to a forming core member.

At block 54, a roll of sheet product is provided by winding the sheetproduct about a forming core member starting at the end of the sheetproduct to which the indicator 30 is applied. At block 56, the formingcore member is removed to provide a coreless roll of sheet producthaving the axial cavity 12. At block 58, the coreless roll is compressedsuch that the axial cavity 12 is substantially collapsed. The indicator30 is visible in the substantially collapsed axial cavity 12.

Additional processes also may be included, and it should be understoodthat the processes depicted in FIG. 5 represent illustrations, and thatother processes may be added or existing processes may be removed,modified, or rearranged without departing from the scope and spirit ofthe present disclosure.

The descriptions of the various examples of the present disclosure havebeen presented for purposes of illustration but are not intended to beexhaustive or limited to the embodiments disclosed. Many modificationsand variations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the described techniques.The terminology used herein was chosen to best explain the principles ofthe present techniques, the practical application or technicalimprovement over technologies found in the marketplace, or to enableothers of ordinary skill in the art to understand the techniquesdisclosed herein.

What is claimed is:
 1. A compressed coreless roll of sheet productcomprising a sheet product comprising a first end and a second end, thesheet product being wound about an axis beginning with the first end andending with the second end, the sheet product partially defining anaxial cavity along the axis, wherein the first end comprises anindicator that is visible when the sheet product roll is compressed suchthat the axial cavity is substantially collapsed.
 2. The compressedcoreless roll of sheet product of claim 1, wherein the indicator iscolored water applied to the first end of the sheet product.
 3. Thecompressed coreless roll of sheet product of claim 1, wherein theindicator is colored adhesive applied to a forming core member andtransferred to the first end of the sheet product.
 4. The compressedcoreless roll of sheet product of claim 1, wherein applying theindicator comprises spraying the indicator on the first end of the sheetproduct.
 5. The compressed coreless roll of sheet product of claim 1,wherein applying the indicator comprises printing the indicator on thefirst end of the sheet product.
 6. A method for forming a compressedcoreless roll of sheet product having an indicator, the methodcomprising: applying the indicator to an end of a sheet product; windingthe sheet product about a forming core member starting at the end of thesheet product to which the indicator is applied; and removing theforming core member to provide a coreless roll of sheet product havingan axial cavity.
 7. The method of claim 6, wherein applying theindicator comprises applying colored water to the end of the sheetproduct.
 8. The method of claim 6, wherein applying the indicatorcomprises applying colored adhesive to the forming core member andtransferring the colored adhesive to the end of the sheet product. 9.The method of claim 6, wherein applying the indicator comprises sprayingthe indicator on the end of the sheet product.
 10. The method of claim6, wherein applying the indicator comprises printing the indicator onthe end of the sheet product.
 11. The method of claim 6, furthercomprising compressing the coreless roll such that the axial cavity issubstantially collapsed.
 12. The method of claim 11, wherein theindicator is visible in the substantially collapsed axial cavity.
 13. Acompressed coreless roll of sheet product produced by way of: applyingan indicator to an end of a sheet product; providing a roll of sheetproduct by winding the sheet product about a forming core memberstarting at the end of the sheet product to which the indicator isapplied; removing the forming core member to provide a coreless roll ofsheet product having an axial cavity; and compressing the coreless rollof sheet product such that the axial cavity is substantially collapsed,wherein the indicator is visible in the substantially collapsed axialcavity.
 14. The compressed coreless roll of sheet product of claim 13,wherein the indicator is colored water applied to the end of the sheetproduct.
 15. The compressed coreless roll of sheet product of claim 13,wherein the indicator is colored adhesive applied to the forming coremember and transferred to the end of the sheet product.
 16. Thecompressed coreless roll of sheet product of claim 13, wherein applyingthe indicator comprises spraying the indicator on the end of the sheetproduct.
 17. The compressed coreless roll of sheet product of claim 13,wherein applying the indicator comprises printing the indicator on theend of the sheet product.
 18. The compressed coreless roll of sheetproduct of claim 13, wherein applying the indicator occurs prior towinding the sheet product about the forming core member.